Photovoltaic module kit including connector assembly for non-penetrating array installation

ABSTRACT

A PV module kit for non-penetrating rooftop installation, including a plurality of PV modules and a plurality of connectors. Each of the PV modules includes a PV laminate and a frame forming a mounting region assembled thereto. The connectors include a male connector having a male fastener extending from a head, and a female connector having a female fastener assembled within a head. The heads are entirely formed of plastic. The kit provides a mounted array state including a junction at which the mounting region of at least two of the PV modules are aligned and interconnected by engagement of the male connector with the female connector. The so-formed junction is substantially electrically insulated. The plurality of connectors can further include a spacer connector including a head forming a bore sized to slidably receive the male fastener, with all of the connector heads being identical.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/492,680, filed Jun. 26, 2009, which claims the benefit of U.S.Provisional Application No. 61/076,479, filed Jun. 27, 2008, the entirecontents of which are hereby incorporated by reference herein. Thisapplication also relates to U.S. application Ser. No. 12/492,640entitled “Ballasted Photovoltaic Module and Module Arrays” U.S.application Ser. No. 12/492,729 entitled “Photovoltaic Module withRemovable Wind Deflector” U.S. application Ser. No. 12/492,802 entitled“Photovoltaic Module and Module Arrays” U.S. application Ser. No.12/492,838 entitled “Photovoltaic Module with Drainage Frame ” all ofwhich were filed on even date herewith and the teachings of each ofwhich are incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with Government support under Contract No.DE-FC36-07GO17043 awarded by the United States Department of Energy. TheGovernment has certain rights in this invention.

BACKGROUND

The present disclosure relates to solar roof tiles. More particularly,it relates to photovoltaic modules and related connector assemblies foreffectuating self-supporting installation.

Solar power has long been viewed as an important alternative energysource. To this end, substantial efforts and investments have been madeto develop and improve upon solar energy collection technology. Ofparticular interest are industrial- or commercial-type applications inwhich relatively significant amounts of solar energy can be collectedand utilized in supplementing or satisfying power needs.

Solar photovoltaic technology is generally viewed as an optimal approachfor large scale solar energy collection, and can be used as a primaryand/or secondary (or supplemental) energy source. In general terms,solar photovoltaic systems (or simply “photovoltaic systems”) employsolar panels made of silicon or other materials (e.g., III-V cells suchas GaAs) to convert sunlight into electricity. More particularly,photovoltaic systems typically include a plurality of photovoltaic (PV)modules (or “solar tiles”) interconnected with wiring to one or moreappropriate electrical components (e.g., switches, inverters, junctionboxes, etc.). The PV module conventionally consists of a PV laminate orpanel generally forming an assembly of crystalline or amorphoussemiconductor devices electrically interconnected and encapsulated. Oneor more electrical conductors are carried by the PV laminate throughwhich the solar-generated current is conducted.

Regardless of an exact construction of the PV laminate, most PVapplications entail placing an array of PV modules at the installationsite in a location where sunlight is readily present. This is especiallytrue for commercial or industrial applications in which a relativelylarge number of PV modules are desirable for generating substantialamounts of energy, with the rooftop of the commercial building providinga convenient surface at which the PV modules can be placed. As a pointof reference, many commercial buildings have large, flat roofs that areinherently conducive to placement of a PV module array, and is the mostefficient use of existing space. While rooftop installation is thushighly viable, certain environment constraints must be addressed. Forexample, the PV laminate is generally flat or planar; thus, if simply“laid” on an otherwise flat rooftop, the PV laminate may not beoptimally positioned/oriented to collect a maximum amount of sunlightthroughout the day. Instead, it is desirable to tilt the PV laminate ata slight angle relative to the rooftop (i.e., toward the southern skyfor northern hemisphere installations, or toward the northern sky forsouthern hemisphere installations). Further, possible PV moduledisplacement due to wind gusts must be accounted for, especially wherethe PV laminate is tilted relative to the rooftop as described above.

To address the above concerns, conventional PV module array installationtechniques have included physically interconnecting each individual PVmodule of the array directly with, or into, the existing rooftopstructure. For example, some PV module configurations have includedmultiple frame members that are physically attached to the rooftop viabolts driven through (or penetrating) the rooftop. While this techniquemay provide a more rigid attachment of the PV module, it is atime-consuming process and permanently damages the rooftop. Also,because holes are formed into the rooftop, distinct opportunities forwater damage arise. More recently, PV module configurations have beendevised for commercial, flat rooftop installation sites in which thearrayed PV modules are self-maintained relative to the rooftop in anon-penetrating manner. More particularly, the PV modules areinterconnected to one another via a series of separate, auxiliarycomponents. One or more wind-deflecting barriers (or “wind deflectors”)are assembled to some or all of the PV modules to reduce (or deflect) amagnitude of wind forces imparted upon an underside of the PV moduleand/or array. Additional ballast is also oftentimes attached to thearray.

In light of the above, the components and techniques employed tointerconnect adjacent PV modules are important to the success of aninstalled, non-penetrating PV module array. In general terms, a typicalarray consists of PV modules arranged in columns and rows, forming arectangular grid. By interconnecting the PV modules, each rowcontributes to the prevention of overturning of an adjacent row. With arigid connection, the weight/mass of one row resists or offsets themoment force created at the connection point with an adjacent rowotherwise being subjected to overturning forces. Each PV moduleeffectively defines four corners; at most locations within the grid,then, four PV modules will come together to define a junction point, andthe corners of the PV four modules forming the junction must be joined.However, there will be many instances within an array when one or moreof these four PV module corners is “missing”. For example, along thesouth edge of the array, only two PV module corners will be joinedtogether at the corresponding junction point. With conventionalnon-penetrating PV module arrays, differing connective components arerequired to accommodate the various junction configurations (e.g., afirst connection device for a four PV module junction and a different,second connection device for a two PV module junction). This, in turn,increases overall costs and installation time, as well as the level ofexpertise required of the installer. Along these same lines,conventional PV module connection techniques entail the use of one ormore hand tools, again increasing installation time and thus costs.Further, metal components are typically used for joining adjacent PVmodules; while viable, the metal couplings (and other metal componentsof the array) raise electrical grounding concerns.

In light of the above, any improvements in the construction of PVmodules and associated connecting components for non-penetratinginstallation as a PV module array will be well-received.

SUMMARY

Some aspects in accordance with the present disclosure relate to a PVmodule kit for non-penetrating installation on a substantially flatinstallation surface. The kit includes a plurality of PV modules and aplurality of connectors. Each of the PV modules includes a PV laminateand a frame assembled thereto. In this regard, the frame forms at leastone mounting region. The connectors include a male connector having amale fastener extending from a head, and a female connector having afemale fastener assembled within the head. The female fastener isadapted for engagement with the male fastener. Further, the heads areentirely formed of plastic. With this in mind, the kit is configured toprovide a mounted array state including a junction at which the mountingregion of at least two of the PV modules are aligned and interconnectedby engagement of the male connector with the female connector. Theso-formed junction is substantially electrically insulated. With thisconstruction, the kit facilitates non-penetrating installation in amanner that does not require additional components to electricallyground the junction. In some embodiments, the male and female fastenersare metal, with the junction having the metal fasteners substantiallyencompassed within plastic provided by the connector heads and the PVmodule frames otherwise forming the junction. In other embodiments, theplurality of connectors further include a spacer connector including ahead forming a bore sized to slidably receive a portion of the malefastener. With some constructions, all of the heads associated with theprovided connectors are identically formed.

Other aspects in accordance with principles of the present disclosurerelate to a PV module kit including a plurality of identically-formed PVmodules and a plurality of identically-formed connector heads. Each ofthe PV modules includes a PV laminate, framework, and four arms. Theframework encompasses a perimeter of the PV laminate. The first andsecond arms extend from, and outwardly beyond, a first side of theframework, whereas the third and fourth arms extend from, and outwardlybeyond, a second end of the framework opposite the first end. Each ofthe arms forms a mounting region, and each of the connector heads form abore. Further, a plurality of male fasteners are attached to and extendfrom some of the connector heads, respectively, to define a plurality ofmale connectors. Similarly, a plurality of female fasteners are attachedto some of the connector heads, respectively, to define a plurality offemale connectors. Finally, at least some of the remaining connectorheads define spacer connectors. With this in mind, the kit is configuredto provide a plurality of installation junctions in a mounted arraystate, with each junction including at least the PV modules mounted toone another. In particular, a plurality of first junctions are provided,each including one of the male connectors and one of the femaleconnectors interconnecting the mounting regions of four of the PVmodules, respectively. Further, a plurality of second junctions areprovided each including one of the male connectors, one of the femaleconnectors, and two of the spacer connectors interconnecting themounting regions of two of the PV modules, respectively. In someembodiments, the framework, the arms, and the heads are all entirelyformed of plastic, thereby minimizing electrical grounding concerns.

Yet other aspects in accordance with the present disclosure relate to aPV installation comprising an array of PV modules and first-fourthconnector assemblies. The array comprises rows and columns of identicalPV modules, including a first PV module having a PV laminate, frameworkencompassing a perimeter of the PV laminate, and first-fourth arms. Thefirst and second arms extend from, and outwardly beyond, a first end ofthe framework, whereas the third and fourth arms extend from, andoutwardly beyond, a second end of the framework opposite the first end.The first connector assembly removably interconnects the first arm witha PV module adjacent the first PV module; the second connector assemblyremovably interconnects the second arm with a PV module adjacent thefirst PV module; etc. In this regard, each of the connector assembliesincludes a male connector comprising a head and a male fastener, and afemale connector comprising an identical head and a female fastener. Insome embodiments, each of the connector assemblies are transitionable byhand between a tightened state, a loosened state, and a removed state.In the tightened state, the corresponding PV modules are rigidlyconnected. In the loosened state, the corresponding PV modules arerotatable relative to the connector assembly. With this construction,where the first and second connector assemblies are in the loosenedstate and the third and fourth connector assemblies are in the removedstate, the first PV module is pivotable relative to the array at thefirst and second arms.

Yet other aspects in accordance with principles of the presentdisclosure relate to a method of non-penetrating installation of a PVmodule array to an installation surface. The method includes providing aplurality of PV modules each including a PV laminate, frameworkencompassing a perimeter of the PV laminate, and a plurality of armsextending from, and outwardly beyond, the framework. Each of the armsforms a mounting region. The PV modules are arranged in an array on theinstallation surface, with the array including rows and columns. Atleast one arm of each of the PV modules is rigidly interconnected withat least one arm of another, adjacent one of the PV modules via acorresponding connector assembly comprising at least a male connectorand a female connector. In this regard, the step of rigidlyinterconnecting the PV modules is accomplished by hand without the useof a tool.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a portion of a photovoltaic module kit inaccordance with principles of the present disclosure;

FIG. 2 is a perspective view of a photovoltaic module useful with thekit of FIG. 1;

FIG. 3 is a side view of the photovoltaic module of FIG. 2 mounted to aninstallation surface;

FIG. 4A is a top view of the photovoltaic module of FIG. 2;

FIG. 4B is a top view of two of the photovoltaic modules of FIG. 2mounted in an end-to-end arrangement;

FIGS. 5A and 5B are perspective views illustrating a mounting regionprovided by the photovoltaic module of FIG. 2;

FIG. 5C is a cross-sectional view of the mounting region of FIGS. 5A and5B;

FIGS. 6A and 6B are perspective views of a head component associatedwith connector assemblies useful with the kit of FIG. 1;

FIG. 6C is a cross-sectional view of the head of FIGS. 6A and 6B;

FIGS. 7A and 7B are perspective views of male and female connectorsuseful with the kit of FIG. 1;

FIG. 8 is a top view of an installed photovoltaic module array providedby the kit of FIG. 1;

FIG. 9A is an enlarged, perspective view of a junction provided with thearray installation of FIG. 8;

FIG. 9B is a simplified, cross-sectional view of the junction of FIG.9A;

FIGS. 9C-9E are perspective views of other junctions provided with thearray installation of FIG. 8;

FIGS. 10A-10C are perspective views of another photovoltaic module arrayinstallation provided by the kit of FIG. 1;

FIG. 11A is a perspective view of an alternative connector assemblyuseful with the kit of FIG. 1;

FIG. 11B is a perspective view of a portion of photovoltaic module arrayprovided by a kit in accordance with principles of the presentdisclosure and incorporating the connector assembly of FIG. 11A; and

FIG. 12 is an enlarged view of a portion of a photovoltaic modulejunction incorporating the connector assembly of FIG. 11A.

DETAILED DESCRIPTION

One embodiment of a photovoltaic (PV) module kit 20 in accordance withprinciples of the present disclosure is shown in FIG. 1. The kit 20includes a plurality of PV modules 22 (one of which is shown in FIG. 1)and a plurality of connector assemblies 24 (one of which is shown inFIG. 1). Details on the various components are provided below. Ingeneral terms, however, the kit 20 is configured to provide anon-penetrating installation of the PV modules 22 to an installationsurface in an array form, with respective ones of the connectorassemblies 24 interconnecting adjacent ones of the PV modules 22 atvarious junctions. The so-effectuated junctions allow the array toconform to the contours of the installation surface, but resistrotational movements/moment forces upon final installation. In someembodiments, the connector assemblies 24 permit subsequent, partial orcomplete removal of one of the PV modules 22 from the array as describedbelow.

The PV modules 22 can be identical, with one of the PV modules 22 beingshown in greater detail in FIG. 2. The PV module 22 includes a PV device30 and a frame 32. A PV laminate 34 of the PV device 30 is encased bythe frame 32, with the frame 32 providing support faces that effectuatea tilted orientation of the PV laminate 34 relative to a flatinstallation surface (e.g., a flat rooftop) in some embodiments. In thisregard, the frame 32 includes at least one arm 36 (referenced generally)providing a mounting region 38 (referenced generally) that is configuredto interface with the connector assembly 24 (FIG. 1) as described below.

The PV module 22 can assume a variety of forms that may or may not beimplicated by FIG. 2. For example, the PV device 30, including the PVlaminate 34, can have any form currently known or in the futuredeveloped that is otherwise appropriate for use a solar photovoltaicdevice. In general terms, the PV laminate 34 consists of an array ofphotovoltaic cells. A glass laminate may be placed over the photovoltaiccells for environmental protection. In some embodiments, thephotovoltaic cells advantageously comprise backside-contact cells, suchas those of the type available from SunPower Corp., of San Jose, Calif.As a point of reference, in backside-contact cells, wirings leading toexternal electrical circuits are coupled on the backside of the cell(i.e., the side facing away from the sun upon installation) forincreased area for solar collection. Backside-contact cells are alsodisclosed in U.S. Pat. Nos. 5,053,083 and 4,927,770, which are bothincorporated herein by reference in their entirety. Other types ofphotovoltaic cells may also be used without detracting from the meritsof the present disclosure. For example, the photovoltaic cells canincorporate thin film technology, such as silicon thin films,non-silicon devices (e.g., III-V cells including GaAs), etc. Thus, whilenot shown in the figures, in some embodiments, the PV device 30 caninclude one or more components in addition to the PV laminate 34, suchas wiring or other electrical components.

Regardless of an exact construction, the PV laminate 34 can be describedas defining a front face 40 and a perimeter 42 (referenced generally inFIG. 2). Additional components (where provided) of the PV device 30 areconventionally located at or along a back face of the PV laminate 34,with the back face being hidden in the view of FIG. 2.

With the above understanding of the PV device 30, and in particular thePV laminate 34, in mind, the frame 32 generally includes framework 50adapted to encompass the perimeter 42 of the PV laminate 34, along withthe at least one arm 36 extending from the framework 50. For example,with the one embodiment of FIG. 2, the frame 32 includes first-fourtharms 36 a-36 d. The arms 36 a-36 d, along with other components of theframe 32, are configured to facilitate arrangement of the PV laminate 34at a tilted or sloped orientation relative to a substantially flatsurface, such as a rooftop. For example, the framework 50 can bedescribed as including or providing a leading end or leading framemember 60, a trailing end or trailing frame member 62, a first side orfirst side frame member 64, and a second side or second side framemember 66.

With the above conventions in mind, FIG. 3 provides a simplifiedillustration of the PV module 22 relative to a flat, horizontal surfaceS. Though hidden in the view of FIG. 3, a location of the PV laminate 34is generally indicated, as is a plane PPV of the PV laminate 34 that isotherwise established by the front face 40 (FIG. 2). Relative to thearrangement of FIG. 3, the frame 32 supports the PV laminate 34 relativeto the flat surface S at a slope or tilt angle □. The tilt angle □ canotherwise be defined as an included angle formed between the PV laminateplane PPV and a plane of the flat surface S. In some embodiments, thearms 36 (two of which are shown in FIG. 3) combine to define a supportface at which the PV module 22 is supported against, and relative to,the flat surface S, with the tilt angle □ being similarly definedbetween the PV laminate plane PPV and a plane of the support face.Regardless, with some constructions, the frame 32 is configured tosupport the PV laminate 34 at a tilt angle □ in the range of 1°-30°, insome embodiments in the range 3°-7°, and in yet other embodiments, at5°. As a point of reference, with tilted PV solar collectioninstallations, the PV laminate 34 is desirably positioned so as to faceor tilt southward (in northern hemisphere installations). Given thistypical installation orientation, then, the leading frame member 60 canbe generally referred to as a south frame member, and the trailing framemember 62 referred to as a north frame member. In other embodiments,however, the frame 32 can be configured to maintain the PV laminate 34in a generally parallel relationship relative to the flat surface S.

Returning to FIG. 2, the framework 50 can assume a variety of formsappropriate for encasing the perimeter 42 of the PV laminate 34, as wellas establishing the desired tilt angle □ (FIG. 3). In some embodiments,the frame members 60-66 are separately formed and subsequently assembledto one another and the PV laminate 34 in a manner generating the unitarystructure upon final construction. Alternatively, other manufacturingtechniques and/or components can be employed such that the framework 50reflected in FIG. 2 is in no way limiting.

As mentioned above, the frame 32 includes at least one of the arms 36a-36 d extending from the framework 50 to provide the at least onemounting regions 38 c, 38 d. With respect to the one non-limitingexample of FIG. 2, the first and second support arms 36 a, 36 b areidentical upon final construction of the frame 30, as are the third andfourth arms 36 c, 36 d. More particularly, the first and second arms 36a, 36 b extend from the framework 50, outwardly and beyond the leadingframe member 60. With this construction, the mounting region 38 a, 38 bformed by each of the first and second arms 36 a, 36 b is locatedlongitudinally beyond (or spaced from) the leading frame member 60.Conversely, the third and fourth arms 36 c, 36 d extend from theframework 50, outwardly and beyond the trailing frame member 62. As withthe first and second arms 36 a, 36 b, extension of the third and fourtharms 36 c, 36 d positions the corresponding mounting regions 38 c, 38 dlongitudinally beyond or spaced from the trailing frame member 62.

The first and second arms 36 a, 36 b can differ from the third andfourth arms 36 c, 36 d in certain respects. For example, a lateralspacing between the first and second arms 36 a, 36 b is less than alateral spacing between the third and fourth arms 36 c, 36 d, and isselected to facilitate assembly of two of the PV modules 22 in anend-to-end arrangement as part of an array. For example, and withreference to FIG. 4A, a first or exterior lateral spacing L1 is definedbetween exterior surfaces 70 of the first and second arms 36 a, 36 b (atleast along the corresponding mounting regions 38 a, 38 b). A second orinterior lateral spacing L2 is defined between interior surfaces 72 ofthe third and fourth arms 36 c, 36 d (at least along the correspondingmounting regions 38 c, 38 d). A distance between the third and fourtharms 36 c, 36 d is slightly greater than that between the first andsecond arms 36 a, 36 b, with the exterior lateral spacing L1approximating the interior lateral spacing L2. With this construction,then, adjacent PV modules 22 a, 22 b can be arranged and mountedend-to-end as part of an arrayed installation as shown in FIG. 4B, withthe first and second arms 36 a, 36 b of the first PV module 22 a beingdisposed between the third and fourth arms 36 c, 36 d of the second PVmodule 22 b. More particularly, the lateral spacing effectuated by thearm pairs 36 a, 36 b and 36 c, 36 d positions the exterior surface 70 ofthe first arm 36 a of the first PV module 22 a against the interiorsurface 72 of the third arm 36 c of the second PV module 22 b. A similararrangement is achieved with respect to the second arm 36 b of the firstPV module 22 a and the fourth arm 36 d of the second PV module 22 b.

Returning to FIG. 2, additional, optional differences between the firstand second arms 36 a, 36 b and the third and fourth arms 36 c, 36 d caninclude the third and fourth arms 36 c, 36 d having a longitudinallength (relative to the trailing frame member 62) being greater than alongitudinal length of the first and second arms 36 a, 36 b (relative tothe leading frame member 60). In some embodiments, this additionallength or surface area facilitates the provision of one or more optionalfeatures with the third and fourth arms 36 c, 36 d. For example, thethird and fourth arms 36 c, 36 d can include or form a deflectorassembly feature 80 (referenced generally for the fourth arm 36 d)configured to releasably associate a wind deflector (not shown) with thePV module 22. Further, a ballast connection feature 82 (referencedgenerally for the third arm 36 c) can be provided, configured tofacilitate releasable association of a ballast tray (not shown) with thePV module 22. Finally, the third and fourth arms 36 c, 36 d can form anenlarged bottom surface 84 (referenced generally for the fourth arm 36c), configured to better ensure stable mounting of the PV module 22 ontoan installation surface (i.e., the bottom surface 84 forms part of thesupport face described above with respect to FIG. 3). Additionalfeatures can be incorporated into one or more of the arms 36 a-36 d;alternatively, one or more of the features 80-84 described above can beomitted.

While the first and second arms 36 a, 36 b can differ from the third andfourth arms 36 c, 36 d as described above, in some embodiments, themounting region 38 associated with each of the arms 36 a-36 d isidentical. With this in mind, FIGS. 5A and 5B illustrate the mountingregion 38 d associated with the fourth arm 36 d in greater detail. Themounting region 38 d is formed or defined at or adjacent a free end 90of the arm 36 d, and includes an interior face 92 (FIG. 5A), an exteriorface 94 (FIG. 5B), and a passage 96. The interior face 92 is relativelyflat or smooth in some embodiments, whereas the exterior face 94 caninclude or be defined by stiffening ribs 98. Alternatively, the exteriorface 94 can be relatively smooth or flat, akin to the interior face 92.With the one embodiment of FIG. 5B, however, an engagement surface 100is provided along the exterior face 94, and is sized to interface with acorresponding component of the connector assembly 24 (FIG. 1) asdescribed below.

Regardless of an exact construction, the interior and exterior faces 92,94 combine to define a thickness TA of the mounting region 38 d as shownin FIG. 5C. The passage 96 extends through the thickness TA, and is openat the interior and exterior faces 92, 94. The passage 96 is sized toreceive a component of the connector assembly 24 (FIG. 1) as describedbelow.

The mounting region 38 d can alternatively assume a wide variety ofother constructions. Similarly, while the arms 36 a-36 d (FIG. 2) havebeen described as having identically-formed mounting regions 38 (FIG.2), in other embodiments, the mounting region 38 can differ for one ormore of the arms 36 a-36 d. In more general terms, then, the mountingregion 38 associated with each of the arms 36 a-36 d is configured tointerface with the connector assemblies 24 (FIG. 1) in a mannerpromoting a frictional, locked engagement therebetween.

Returning to FIG. 1, the connector assemblies 24 each include at least amale connector 110 and a female connector 112. Further, at least some ofthe connector assemblies 24 includes one or more spacer connectors 114.Details on the various connectors 110-114 are provided below. In generalterms, however, each of the connector formats 110-114 includes a head116, with the heads 116 being identical for all of the connectors110-114 (as well as for all of the connector assemblies 24 additionallyprovided with the kit 20).

The head 116 is shown in greater detail in FIGS. 6A-6C. The head 116 isentirely formed of plastic or other electrically non-conductive material(e.g., PPO/PS (Polyphenylene Oxide co-polymer/polystyrene blend) or PET(Polyethylene Terephthalate)), and defines an interior side 120, anexterior side 122, and a perimeter 124. A thickness TH (FIG. 6C) isdefined between the sides 120, 122, with the head 116 further forming abore 126 that extends between, and is open relative to, the sides 120,122. As made clear below, the head thickness TH is commensurate with themounting region thickness TA (FIG. 5C) referenced above.

While the head 116 can assume a variety of shapes and sizes differingfrom those reflected in FIGS. 6A and 6B, in some embodiments theperimeter 124 is generally circular, defining one or more grooves 128conducive for grasping by a user's finger(s). The sides 120, 122 canalso assume a variety of forms, with the head 116 including, in someembodiments, one or more stiffening ribs 130 (FIG. 6B) that otherwiseextend from the second side 122. In addition, at least the interior side120 forms an engagement surface 132. The engagement surface 132 isadapted to establish frictional engagement with the engagement surface100 (FIG. 5B) of the corresponding frame mounting region 38 (FIG. 1)during use, and can have the ring-like shape as shown. Where theengagement surface 132 is formed as a protrusion of the correspondingside (e.g., the interior side 120 as shown in FIG. 6A), the headthickness TH is defined at (or relative to) the engagement surface 132.

As described below, the head 116 can be used as part of any of the male,female, or spacer connectors 110-114 (FIG. 1) of the present disclosure,and thus is a universal component to the kit 20 (FIG. 1). For example,the head 116 serves as the spacer connector 114 without furthermodification. An appropriate fastener is assembled to the head 116 toform the male connector 110 or the female connector 112. For example,the bore 126 is sized and shaped to frictionally receive and maintain amale or female fastener as described below. As best shown in FIG. 6C, insome embodiments the bore 126 includes a first segment 134 and a secondsegment 136. The first segment 134 extends from, and is open relativeto, the interior side 120. The second segment 136 extends from, and isopen relative to, the exterior side 122, and has a transverse dimensiongreater than that of the first segment 134. More particularly, thesecond segment 136 is sized and shaped to maintain a male or femalefastener, and can have a hexagonal shape (as illustrated in FIG. 6B).Other shapes are also acceptable in alternative embodiments, with thecorresponding male or female fastener exhibiting a similar shape forsubsequent assembly. In yet other embodiments, differing manufacturingtechniques can be employed for coupling the fastener to the head 116and/or the bore 126 can be uniform. Regardless, by providing the head116 as a universal item, the differing connectors 110-114, and thus theplurality of connector assemblies 24, are readily manufactured on a massproduction basis.

With the above understanding of the head 116 in mind, the male connector110 includes a male fastener 140 assembled to, and extending from, thehead 116 as shown in FIGS. 7A and 7B. For purposes of clarification, themale connector head is labeled as “116 a” in FIGS. 7A and 7B. The malefastener 140 can assume a variety of forms, and in some embodiments is athreaded metal machine bolt including a base 142 (best seen in FIG. 7B)and an exteriorly threaded shaft 144. The base 142 can be connectedwithin the bore 126 of the head 116 a in various manners. For example,the base 142 can be sized to be frictionally retained within the bore126 (e.g., hexagonal shape); the head 116 a can be molded about the base142; etc. Regardless, the shaft 144 projects from the interior side 120of the head 116 a, terminating at an end 146. Extension of the shaft 144from the interior side 120 defines a male fastener extension length. Thebase 142 is effectively embedded within the thickness TH (best shown inFIG. 6C) of the head 116 a, and is laterally spaced from the exteriorside 122 (FIG. 7B). Thus, while the base 142 is exteriorly accessiblevia the exterior side 122/bore 126, the exterior side 122 exteriorlyshrouds or protects the exposed portion of the base 142.

The female connector 112 includes the head (labeled as “116 b” in FIGS.7A and 7B for purposes of clarification), and a female fastener 150. Thefemale fastener 150 can assume various forms, and is generallyconfigured to selectively engage with the male fastener 140. Thus, insome embodiments, the female fastener 150 is an internally threadedmetal nut. As with the male fastener 140, the female fastener 150 can beassembled to the head 116 b in a number of manners, including insertingand frictionally retaining the female connector/nut 150 within the bore126 of the head 116 b. Thus, where the bore 126 has a hexagonal shape,the female connector/nut 150 is also hexagonal. Alternatively, the head116 b can be molded about the female connector 150. Regardless, thefemale connector 150 is effectively embedded within the thickness TH(best shown in FIG. 6C) of the head 116 b. With this configuration,while the female connector 150 is exteriorly accessible via the bore126, the sides 120, 122 exteriorly shroud and protect the femaleconnector 150.

Returning to FIG. 1, the kit 20 provides for a multiplicity of differentarrayed configurations in which the connector assemblies 24 interconnectthe arrayed PV modules 22 in a non-penetrating manner. For example, FIG.8 illustrates one simplified array 170 facilitated by the kit 20 inaccordance with the present disclosure. The array 170 consists offirst-fourth PV modules 22 a-22 d, and first-fifth connector assemblies24 a-24 e. In the mounted array state of FIG. 8, one or more junctions172 (referenced generally) are provided at which two or more of the PVmodules 22 a-22 d are interconnected via a corresponding one of theconnector assemblies 24 a-24 e.

For example, a first junction 172 a defines a common interconnectionbetween each of the four PV modules 22 a-22 d. The first junction 172 ais shown in greater detail in FIG. 9A, and consists of the mountingregions 38 (best identified in FIG. 2) of the first arm 36 a of thefirst PV module 22 a, the third arm 36 c of the third PV module 22 c,the fourth arm 36 d of the fourth PV module 22 d, and the second arm 36b of the second PV module 22 b, as well as the first connector assembly24 a. The first connector assembly 24 a includes one of the maleconnectors 110 and one of the female connectors 112. Though hidden inthe view of FIG. 9A, the passages 96 associated with the mounting region38 of each of the arms 36 a-36 d are aligned with one another, and themale connector 110 is engaged with the female connector 112. Moreparticularly, the shaft 144 extends through the aligned passages 96, andis threadably engaged with the female fastener 150 as shown in FIG. 9B.In this regard, the arms 36 a-36 d can be rigidly affixed relative toone another by screwing/tightening of the male and female connectors110, 112, such that the head 116 of the female connector 112frictionally engages the first arm 36 a, and the head 116 of the maleconnector 110 frictionally engages the second arm 36 b in a lockedstate. In some embodiments, the heads 116 are readily grasped by thehands of an installer, such that the locked junction can be achieved byhand tightening, without use of tools. Where desired, however, a tool(s)can be employed to further tighten the connector assembly 24 a.

With embodiments in which at least the arms 36 a-36 d of each of the PVmodules 22 a-22 d are formed of plastic or other non-electricallyconductive material, the resultant first junction 172 a is characterizedas being substantially electrically insulated. More particularly, andwith continued reference to FIG. 9B, the male fastener extension lengthof the shaft 144 is less than a combined thickness TC defined by thearms 36 a-36 d and the head 116 of the female connector 112. With thisconstruction, while in the locked state of FIG. 9B in which the shaft144 extends to and threadably engages with the female fastener 150, theshaft 144 does not overtly project outwardly beyond the female connector112. Thus, an entirety of the shaft 144 is essentially transverselyencompassed by plastic or other electrically non-conductive material.Further, while the base 142 of the male fastener 140 as well as thefemale fastener 150 are somewhat exposed via the bore 126 of thecorresponding head 116, the base 142 and the female fastener 150 arelaterally and partially longitudinally shrouded or covered by thecorresponding head 116. Thus, the heads 116 effectively render the metalcomponents 142, 150 inaccessible by an installer's fingers, such thatthat the first junction 172 a does not require electrical grounding.Finally, FIG. 9B generally reflects frictional engagement between thefirst arm 36 a and the head 116 of the female connector 112, as well asfrictional engagement between the second arm 36 b and the head 116 ofthe male connector 110 in the locked state.

Returning to FIG. 8, a second junction 172 b is formed between thesecond and fourth PV modules 22 b, 22 d by the second connector assembly24 b. As shown in FIG. 9C, the second junction 172 b consists of themounting regions 38 (referenced generally) of the first arm 36 a of thesecond PV module 22 b and the third arm 36 c of the fourth PV module 22d, as well as the second connector assembly 24 b. The second connectorassembly 24 b includes one of the male connectors 110, one of the femaleconnectors 112, and two of the spacer connectors 114 a, 114 b. Onceagain, the mounting region 38 of each of the arms 36 b, 36 d arealigned, with the shaft 144 (FIGS. 7A and 7B) extending through thecorresponding passages 96 (hidden in FIG. 9C). The spacer connectors 114a, 114 b are similarly arranged relative to the shaft 144, with theshaft 144 extending through the corresponding bores 126 (FIGS. 6A and6B). The male connector 110 is engaged with the female connector 112 aspreviously described, with tightening of the components 110, 112effectuating a rigid, frictional lock or engagement between the arms 36b, 36 d via the spacer connectors 114 a, 114 b. While the spacerconnectors 114 a, 114 b are illustrated as being arranged at oppositesides of the arms 36 a or 36 c, respectively, in other constructions,the second junction 172 b can include both of the spacer connectors 114a, 114 b being positioned at one side of either of the arms 36 a, 36 c.Regardless, the thickness TH (FIG. 6C) of each of the spacer connectors114 a, 114 b (via the corresponding head 116) is akin to the mountingregion thickness TA (FIG. 5C) of each of the arms 36 a, 36 c. As aresult, the combined thicknesses of the arms 36 a, 36 c, the spacerconnectors 114 a, 114 b, and the head 116 of the female connector 112encompass the shaft 144. Thus, the second junction 172 b issubstantially electrically insulated as described above with respect tothe first junction 172 a (FIG. 8).

Returning to FIG. 8, a third junction 172 c is essentially identical tothe second junction 172 b described above, except that it is formed bythe mounting regions 38 (referenced generally) of the second arm 36 b ofthe first PV module 22 a, and the fourth arm 36 d of the third PV module22 c, as well as the third connector assembly 24 c. In this regard,though not fully visible in FIG. 8, the third connector assembly 24 cincludes one of the male connectors 110, one of the female connectors112, and two of the spacer connectors 114 as described above.

A fourth junction 172 d of the array 170 includes the mounting regions38 (referenced generally) of the first arm 36 a of the third PV module22 c and the second arm 36 b of the fourth PV module 22 d, as well asthe fourth connector assembly 24 d. Once again, the mounting regions 38associated with the arms 36 a, 36 b are aligned, with the fourthconnector assembly 24 d establishing a rigid connection between themounting regions 38. With reference to FIG. 9D, the fourth connectorassembly 24 d includes one of the male connectors 110, one of the femaleconnectors 112, and two of the spacer connectors 114 a, 114 b. Thespacer connectors 114 a, 114 b are assembled over the shaft 144 (FIGS.7A and 7B) of the male connector 110, and positioned between the arms 36a, 36 b. The head thickness TH (FIG. 6C) of the spacer connectors 114 a,114 b/heads 116 are commensurate with the thickness TA (FIG. 5C) of thearm mounting regions 38, such that upon final assembly, the metal malefastener 140 and the metal female fastener 150 (FIGS. 7A and 7B) aresubstantially electrically insulated as previously described.

Returning to FIG. 8, a fifth junction 172 e includes the mountingregions 38 (referenced generally) of the third arm 36 c of the first PVmodule 22 a and the fourth arm 36 d of the second PV module 22 b, aswell as the fifth connector assembly 24 e. As shown in FIG. 9E, thefifth connector assembly 24 e includes one of the male connectors 110,one of the female connectors 112, and two of the spacer connectors 114a, 114 b. Once again, the mounting regions 38 provided by the arms 36 c,36 d are aligned, and are rigidly interconnected via the fifth connectorassembly 24 e. As shown, the spacer connectors 114 a, 114 b arepositioned at opposite sides of the arms 36 c, 36 d and serve to ensuresubstantial electrical insulation of the fifth junction 172 e asdescribed above. Notably, FIG. 9E illustrates an optional wind deflector180 a, 180 b assembled to the PV modules 22 a, 22 b, respectively.

The array 170 of FIG. 8 is but one example of a non-penetratinginstallation provided by PV module kits in accordance with the presentdisclosure to a substantially flat surface (e.g., maximum pitch of2:12). Any number of PV module can be interconnected to one another viaany number of the connector assemblies 24. In general terms, one of theconnector assemblies 24 is provided for each PV module junction. Wherethe junction in question consists of four PV modules, the correspondingconnector assembly includes one of the male connectors 110 and one ofthe female connectors 112. If less than four PV modules are joinedtogether at the junction in question, then one of the spacer connectors114 is inserted for every “missing” PV module 22. The spacerconnector(s) 114 prevent excess bolt material from being exposed, andthus limits potential electrocution hazards. Further, the connectorassemblies 24 establish a rigid connection between the PV module frames(via friction) such that in an arrayed format, each row of the arraywill contribute to the prevention of an adjacent row overturning byresisting the moment forces created at the corresponding junctions.

In addition to promoting rapid assembly of the desired array withoutrequiring use of hand tools, PV module kits, and corresponding assembledPV module arrays, in accordance with the present disclosure optionallyfacilitate straightforward modification of an installed array. Moreparticularly, the connector assemblies 24 can be assembled to thecorresponding PV modules 22 in the locked state as described abovewhereby the corresponding PV modules 22 are frictionally, rigidlyinterconnected. In addition, the connector assemblies 24 can be arrangedin a loosened state whereby the corresponding PV modules 22 are looselyinterconnected, but moveable relative to one another about the connectorassembly 24 (i.e., the male connector 110 is coupled to the femaleconnector 112, but the components 110, 112 are not sufficientlytightened rigidly engage the PV modules 22). In the loosened state,adjacent ones of the PV modules 22 comprising a particular junction canbe slightly rotated relative to one another to accommodate variationsalong the installation surface. Thus, the corresponding array readilyconforms to a roof having non-uniform flatness (i.e., with localizedchanges in pitch) by the “adjustment” of the connection/junction pointsbefore tightening of the corresponding connector assembly (e.g., toaccommodate changes in pitch in the north-south direction). An inherentflexibility of the PV module arms can further promote conformance of thearray to installation surface non-uniformities (e.g., for changes inpitch in the east-west direction).

In addition to the above, loosening and/or removal of two (or more) ofthe connector assemblies 24 associated with a particular PV module 22permits more overt movement of the PV module 22. For example, FIG. 10Aillustrates an alternative PV module array 190 consisting of first-ninthPV modules 22 a-22 i arranged in columns 192 and rows 194. The PVmodules 22 a-22 i are generally interconnected to one another atjunctions via corresponding ones of the connector assemblies 24(referenced generally). With respect to the fifth PV module 22 e,however, the connector assemblies have been removed from engagement (ornot initially assembled to) with the first and second arms 36 a, 36 bthereof. Further, the connector assemblies 24 a-24 b associated with thethird and fourth arms 36 c, 36 d, respectively, are in a loosened statewhereby the arms 36 c, 36 d are connected with the adjacent PV modules22 d, 22 f-22 i, but are moveable relative thereto. In particular, thefifth PV module 22 e can be rotated relative to the array 190, with thearms 36 c, 36 d pivoting about the male fastener 140 (FIGS. 7A and 7B)associated with the first and second connector assembly 24 a, 24 b,respectively. FIG. 10B illustrates a similar, rotated arrangement of thefifth PV module 22 e relative to the array 190, with the fifth PV module22 e pivoting at the first and second arms 36 a, 36 b. Finally, FIG. 10Creflects the fifth PV module 22 e being entirely removable from thearray 190 by removing the corresponding connector assemblies 24 (notshown) from the first-fourth arm 36 a-36 d.

By disengaging two of the connector assemblies 24 from the arm pairs 36a, 36 b or 36 c, 36 d of any given PV module 22 within an array, the PVmodule 22 can be rotated upward in order to provide access to theinstallation surface (i.e., rooftop). Further, if all four connectionsassociated with a particular PV module 22 are removed, the PV module 22can be lifted completely free of the array.

The connector assemblies 24 described above are but one acceptableconfiguration in accordance with aspects of the present disclosure. Forexample, the head 116 (FIG. 6A) can include or form transverselyextending protrusions (e.g., a sunburst pattern) that directly engagewith corresponding slots formed in or by the mounting region 38 providedby the PV module frame 30 (FIG. 2). With this configuration, a morerigid engagement can be achieved via discrete angle interface.

Yet another embodiment connector assembly 200 is shown in FIG. 11A andincludes a connector or head 202 forming a plurality of ledges 204 a-204c, a male fastener 206 and a female fastener 208 (e.g., a bore). Thestepped arrangement of the ledges 204 is sized to fit within a hole 210provided by a corresponding PV module frame 212 as shown in FIG. 11B. Inthis regard, the hole 210 is defined by a plurality of stepped shoulders214 a-214 c that correspond with the stepped ledges 204 a-204 c (FIG.11A).

During use, and with reference to FIG. 12, a pair of the connectors 202(one of which is visible in FIG. 12) are assembled “across” anarrangement of PV module frame arms 36 a′-36 d′, with the male fastener206 (FIG. 11A) of each connector 202 passing through the holes 210 (FIG.11B) of the arms 36 a′-36 d′ and engaging with the female fastener 208of the other connector 202. As a result, the connector assembly 200 canbe deployed to interconnect four of the PV module arms 36 a′-36 d′ asshown in FIG. 12. Where the junction in question consists of only two ofthe arms 36 a′-36 d′, the stepped interface relationship between theledges 204 a-204 c (FIG. 11A) and the shoulders 214 a-214 c (FIG. 11B)positions the connectors 202 at a desired location relative to oneanother for “locking” the two arms 36 a-36 d′. Regardless, the connectorassembly 200 provides a rigid interconnection (e.g., resistance torotational movement of the connected PV modules) due to an inability ofthe square-like head 202 to rotate within the square-like hole 210. Insome embodiments, a few degrees of rotation are designed into the partsto accommodate localized changes in pitch of the installation surface.

Although the present disclosure has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges can be made in form and detail without departing from the spiritand scope of the present disclosure. For example, while the frame hasbeen described as including four of the arms, in other embodiments, alesser or greater number can be provided. Along these same lines, whilethe various arms have been described as being formed as part of certainframe members (e.g., the side frame members), in other embodiments, oneor more of the arms can project from (or be formed as part of) other(s)of the frame members.

1. A photovoltaic module kit for non-penetrating installation on asubstantially flat installation surface, the kit comprising: a pluralityof photovoltaic modules each including: a photovoltaic laminate, aframework encompassing a perimeter of the photovoltaic laminate andforming a mounting region; and a plurality of connectors including: amale connector having a male fastener extending from a head, a femaleconnector having a female fastener adapted for engagement with the malefastener and assembled within a head, wherein the male and femalefasteners are metal; wherein the kit is configured to provide a mountedarray state having a first junction at which the mounting regions of atleast two of the photovoltaic modules are aligned and interconnected byengagement of the male connector with the female connector, the firstjunction being substantially electrically insulated, wherein the firstjunction includes the metal fasteners substantially encompassed withinplastic, wherein the male fastener is a bolt having a shaft defining alength, and further wherein the first junction includes contiguouslyarranged plastic components forming a passageway, a length of thepassageway combined with a thickness of the head of the female connectorbeing greater than the length of the bolt.
 2. The kit of claim 1,wherein the bolt has a base embedded within the head of the maleconnector.
 3. The kit of claim 2, wherein the female connector is a nutembedded within the corresponding head.
 4. The kit of claim 1, whereinthe plurality of connectors further includes: a spacer connectorincluding a head forming a bore sized to slidably receive a portion ofthe male fastener.
 5. The kit of claim 4, wherein the heads areidentical.
 6. The kit of claim 5, wherein each of the heads has acircular perimeter forming a plurality of finger grooves.
 7. The kit ofclaim 4, wherein the first junction further includes two of the spacerconnectors.
 8. The kit of claim 1, wherein the frame of each of thephotovoltaic modules is entirely formed of plastic.
 9. The kit of claim1, wherein the heads are entirely formed of plastic.
 10. A photovoltaicmodule kit for non-penetrating installation on a substantially flatinstallation surface, the kit comprising: a plurality of photovoltaicmodules each including: a photovoltaic laminate, a frameworkencompassing a perimeter of the photovoltaic laminate and forming amounting region; and a plurality of connectors including: a maleconnector having a male fastener extending from a head, a femaleconnector having a female fastener adapted for engagement with the malefastener and assembled within a head, wherein the heads are identical,and a spacer connector including a head forming a bore sized to slidablyreceive a portion of the male fastener; wherein the kit is configured toprovide a mounted array state having a first junction at which themounting regions of at least two of the photovoltaic modules are alignedand interconnected by engagement of the male connector with the femaleconnector, the first junction being substantially electricallyinsulated.
 11. The kit of claim 10, wherein the male and femalefasteners are metal, wherein the first junction includes the metalfasteners substantially encompassed within plastic, wherein the malefastener is a bolt having a shaft defining a length, and further whereinthe first junction includes contiguously arranged plastic componentsforming a passageway, a length of the passageway combined with athickness of the head of the female connector being greater than thelength of the bolt, and wherein the bolt has a base embedded within thehead of the male connector.
 12. The kit of claim 11, wherein the femaleconnector is a nut embedded within the corresponding head.
 13. The kitof claim 10, wherein each of the heads has a circular perimeter forminga plurality of finger grooves.
 14. The kit of claim 10, wherein thefirst junction further includes two of the spacer connectors.
 15. Thekit of claim 10, wherein the frame of each of the photovoltaic modulesis entirely formed of plastic.
 16. The kit of claim 10, wherein theheads are entirely formed of plastic.
 17. A photovoltaic module kit fornon-penetrating installation on a substantially flat installationsurface, the kit comprising: a plurality of photovoltaic modules eachincluding: a photovoltaic laminate, a framework encompassing a perimeterof the photovoltaic laminate and forming a mounting region; and aplurality of connectors including: a male connector having a malefastener extending from a head, a female connector having a femalefastener adapted for engagement with the male fastener and assembledwithin a head, and a spacer connector including a head forming a boresized to slidably receive a portion of the male fastener; wherein thekit is configured to provide a mounted array state having a firstjunction at which the mounting regions of at least two of thephotovoltaic modules are aligned and interconnected by engagement of themale connector with the female connector, the first junction beingsubstantially electrically insulated, and wherein the first junctionfurther includes two of the spacer connectors.
 18. The kit of claim 17,wherein the male and female fasteners are metal, wherein the firstjunction includes the metal fasteners substantially encompassed withinplastic, wherein the male fastener is a bolt having a shaft defining alength, and further wherein the first junction includes contiguouslyarranged plastic components forming a passageway, a length of thepassageway combined with a thickness of the head of the female connectorbeing greater than the length of the bolt, and wherein the bolt has abase embedded within the head of the male connector.
 19. The kit ofclaim 18, wherein the female connector is a nut embedded within thecorresponding head.
 20. The kit of claim 17, wherein each of the headshas a circular perimeter forming a plurality of finger grooves.
 21. Thekit of claim 17, wherein the frame of each of the photovoltaic modulesis entirely formed of plastic.
 22. The kit of claim 17, wherein theheads are entirely formed of plastic.